mitsubishii4b12

8/10/2019 mitsubishii4b12

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11C-1

GROUP 11C

ENGINEMECHANICAL

CONTENTS

GENERAL INFORMATION. . . . . . . . 11C-2

ENGINE DIAGNOSIS. . . . . . . . . . . . . 11C-2

SERVICE SPECIFICATIONS. . . . . . . 11C-3

SEALANTS . . . . . . . . . . . . . . . . . . . . 11C-4

SPECIAL TOOLS. . . . . . . . . . . . . . . . 11C-5

ON-VEHICLE SERVICE. . . . . . . . . . . 11C-8

DRIVE BELT TENSION CHECK. . . . . . . . . 11C-8

AUTO-TENSIONER CHECK . . . . . . . . . . . 11C-9

VALVE CLEARANCE CHECK ANDADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . 11C-11

IGNITION TIMING CHECK. . . . . . . . . . . . . 11C-11

CURB IDLE SPEED CHECK . . . . . . . . . . . 11C-13

IDLE MIXTURE CHECK . . . . . . . . . . . . . . . 11C-14

COMPRESSION PRESSURE CHECK. . . . 11C-16

MANIFOLD VACUUM CHECK . . . . . . . . . . 11C-17

CRANKSHAFT PULLEY. . . . . . . . . . 11C-19

REMOVAL AND INSTALLATION . . . . . . . . 11C-19

CAMSHAFT. . . . . . . . . . . . . . . . . . . . 11C-24

REMOVAL AND INSTALLATION . . . . . . . . 11C-24

VALVE STEM SEAL. . . . . . . . . . . . . . 11C-38

REMOVAL AND INSTALLATION. . . . . . . . 11C-38

OIL PAN. . . . . . . . . . . . . . . . . . . . . . . 11C-46


INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11C-48

CRANKSHAFT OIL SEAL . . . . . . . . . 11C-49


CYLINDER HEAD GASKET . . . . . . . . 11C-52


TIMING CHAIN. . . . . . . . . . . . . . . . . . 11C-64


BALANCER TIMING CHAIN, BALANCERSHAFT AND OIL PUMP MODULE. . . 11C-72


BALANCER SHAFT AND OIL PUMPMODULE. . . . . . . . . . . . . . . . . . . . . . . 11C-76


ENGINE ASSEMBLY. . . . . . . . . . . . . 11C-81



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GENERAL INFORMATION

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ENGINE MECHANICAL 11C-2

GENERAL INFORMATIONM1111000101605

The 4B12 (2.4 L) engine is an in-line four-cylinderengine. The cylinder numbers are assigned as1-2-3-4 from the front of the engine (timing chainside). The firing order is 1-3-4-2.

ENGINE DIAGNOSISM1111000700433

ITEMS SPECIFICATIONS

Type In-line DOHC

Number of cylinders 4

Bore mm (in) 88 (3.5)

Stroke mm (in) 97 (3.8)

Total displacement cm3(cu. in) 2,360 (144.0)

Compression ratio 10.5

Firing order 1-3-4-2

Valve timing Intake valve Opens (BTDC) 40 0

Closes (ABDC) 64 24

Exhaust valve Opens (BBDC) 24 44

Closes (ATDC) 0 20

SYMPTOMS PROBABLE CAUSE REMEDY

Compression is toolow

Blown cylinder head gasket Replace the gasket.

Worn or damaged piston rings Replace the rings.

Worn piston or cylinder Repair or replace the piston and/or thecylinder block.

Worn or damaged valve seat Repair or replace the valve and/or theseat ring

Drop in engine oilpressure

Engine oil level is too low Check the engine oil level.

Malfunction of engine oil pressure switch Replace the engine oil pressure switch.

Clogged oil filter Install a new filter.

Worn oil pump gears or cover Replace the gears and/or the cover.

Thin or diluted engine oil Change the engine oil to the correctviscosity.

Stuck (opened) oil relief valve Repair the relief valve.

Excessive bearing clearance Replace the bearings.

Engine oil pressuretoo high

Stuck (closed) oil relief valve Repair the relief valve.

Noisy valves Incorrect valve clearance Adjust valve clearance

Thin or diluted engine oil (low engine oilpressure)

Change the engine oil.

Worn or damaged valve stem or valveguide

Replace the valve and/or the guide.


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SERVICE SPECIFICATIONS

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SERVICE SPECIFICATIONSM1111000301836

Connecting rodnoise/main bearingnoise

Insufficient oil supply Check the engine oil level.

Thin or diluted engine oil Change the engine oil.

Excessive bearing clearance Replace the bearings.

SYMPTOMS PROBABLE CAUSE REMEDY

Item Standard value Limit

Drive belt tension Vibration frequency Hz(Reference)

102 129

Tension N (lb) (Reference) 248 400 (56 90)

Valve clearance (at cold) mm (in) Intake valve 0.20 0.03(0.008 0.001)

Exhaust valve 0.30 0.03(0.012 0.001)

Basic ignition timing at idle 5BTDC 3

Actual ignition timing at curb idle Approximately10 BTDC

CO contents % 0.5 or less

HC contents ppm 100 or less

Curb idle speed r/min 650 100

Compression pressure (200 r/min) kPa (psi) 1,440 (208.8) Minimum 1,000(145.0)

Compression pressure difference of all cylinder kPa (psi) 100 (14.5)

Intake manifold vacuum at curb idle kPa (in Hg) Minimum 60(17.8)


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SPECIAL TOOLS

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SPECIAL TOOLSM1111000602272

Tool Tool number and name Supersession Application

MB992080Belt tension meter seta: MB9912081

Belt tension meterb: MB992082Mic assembly

Tool not available Drive belt tension(frequency) measurement

MB991958Scan tool (M.U.T.-III subassembly)a: MB991824

Vehicle communicationinterface (V.C.I.)

b: MB991827M.U.T.-III USB cable

c: MB991910

M.U.T.-III main harness A(Vehicles with CANcommunication system)

d: MB991911M.U.T.-III main harness B(Vehicles without CANcommunication system)

e: MB991914M.U.T.-III main harness C(for Chrysler models only)

f: MB991825M.U.T.-III adapter harness

g: MB991826M.U.T.-III trigger harness

MB991824-KIT

NOTE: MB991826

M.U.T.-III Trigger

Harness is not

necessary when

pushing V.C.I.

ENTER key.

CAUTION

For vehicles with CAN

communication, use

M.U.T.-III main harness A

to send simulated vehicle

speed. If you connect

M.U.T.-III main harness B

instead, the CAN

communication does not

function correctly.

Ignition timing check Curb idle speed check Idle mixture check Erasing the diagnostic

trouble code

B992080

a

b

MB991910

MB991826

MB991958

MB991911

MB991914

MB991824

MB991827

MB991825

DO NOT USE

a

b

c

d

e

f

g

DO NOT USE


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SPECIAL TOOLS

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MB992278Belt tension release wrench

Auto-tensioner tensionrelease

MB990767Front hub and flange yokeholder

MB990767-01 Holding the crankshaftpulley

MD998719Pin

MIT308239

MB992103Chain tension release bar

Camshaft and camshaftsprocket assembly(exhaust side) removal

MD998772Valve spring compressor

General servicetool

Valve spring compression

MB992090Retainer holder attachment

MB992089Retainer holder C

MB992085Valve stem seal pliers

Valve stem seal removal


MB992278

B990767

D998719

B992103

MD998772

B992090


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ON-VEHICLE SERVICE

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ON-VEHICLE SERVICEDRIVE BELT TENSION CHECK

M1111003102997

1. Remove the radiator condenser tank mounting bolts.

2. Move the radiator condenser tank to a place where it will not

be a hindrance when checking the drive belt tension.

MB991454Engine hanger balancer

MZ203827-01 Supporting the engineand transaxle assemblyduring removal andinstallation of the timingchain

Supporting the engineassembly duringremoval and installationof the transaxleassembly

NOTE: Special tool

MB991454 is a part of

engine hanger attachment

set MB991453.

MB991895Engine hanger

Tool not available

MB991928Engine hangera: MB991929

Joint (50) 2b: MB991930

Joint (90) 2c: MB991931Joint (140) 2

d: MB991932Foot (standard) 4

e: MB991933Foot (short) 2

f: MB991934Chain and hook assembly

Tool not available

MB992201Engine hanger plate

Transaxle assemblyremoval


B991454

MB991895

B991928

a

b

c

d

e

f

Slide bracket (HI)

B992201


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ON-VEHICLE SERVICE

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CAUTION

Check the drive belt tension after turning the crankshaft

clockwise one turn or more.

3. Make sure that the indicator mark on the auto-tensioner iswithin the area marked with A in the illustration.

4. If the mark is out of the area A, replace the drive belt (Referto P.11C-19.)

NOTE: The drive belt tension check is not necessary as the

auto-tensioner is adopted.

5. Tighten the radiator condenser tank mounting bolts to thespecified torque.

Tightening torque: 12 2 N m (102 22 in-lb)

AUTO-TENSIONER CHECKM1111003001942

OPERATION CHECK

Required Special Tool:MB992278: Belt tension release wrench

1. Turn off the engine from the idle state then check to see thatthe drive belt is not protruding from the pulley width of theauto-tensioner.

2. Remove the drive belt (Refer to P.11C-19.)

3. Using the special tool MB992278 and a straight offsetwrench as shown, check that no binding is present byturning the auto-tensioner in the left and right directions.

4. If there are any problems in the procedure 1 or 3, replacethe auto-tensioner (Refer to P.11C-64.)

5. Install the drive belt (Refer to P.11C-19.)

FUNCTION CHECK

The auto-tensioner can be checked whether it is in good condi-tion by checking its tension..

Required Special Tools:

MB992080: Belt Tension Meter Set MB992081: Belt Tension Meter MB992082: Mic Assembly

1. Check the tension of the drive belt (Refer to P.11C-8.)

2. Check the tension of the drive belt in the followingprocedures.

AC506730AC

A

Indicator mark

Auto-tensioner

AC804028AE

Auto-tensioner

MB992278


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ON-VEHICLE SERVICE

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1. Check the tension of the drive belt (Refer to P.11C-8.)

2. Use a belt tension gauge in the middle of the belt betweenthe pulleys shown in the figure (at the place indicated by thearrow) to check that the belt tension is within the standardvalue.

Standard value: 248 400 N (56 90 lb)

3. If not within the standard value, replace the auto-tensioner(Refer to P.11C-64.)

VALVE CLEARANCE CHECK AND ADJUSTMENTM1111001501509

Refer to GROUP00, Maintenance service Intake And Exhaust Valve Clearance (Inspect And Adjust)

P.00-85.

IGNITION TIMING CHECK M1111001702755

Required Special Tool:

MB991958: Scan Tool (M.U.T.-III Sub Assembly) MB991824: V.C.I. MB991827: M.U.T.-III USB Cable MB991910: M.U.T.-III Main Harness A

1. Before inspection, set the vehicle in the following condition: Engine coolant temperature: 80 95C (176 203F) Lights and all accessories: OFF Transaxle: Neutral (P range on vehicles with CVT)

NOTE: On vehicles for Canada, the headlight, taillight, etc.

remain lit even when the lighting switch is in "OFF" positionbut this is no problem for checks.

AC506733AD

Generatorpulley

Idler pulley

Idler pulley

Crankshaftpulley

Power steeringoil pump pulley

Belttensiongauge
http://gr00002700-00.pdf/http://gr00002700-00.pdf/


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ON-VEHICLE SERVICE

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CAUTION

To prevent damage to scan tool MB991958, always turn the

ignition switch to the "LOCK" (OFF) position before con-

necting or disconnecting scan tool MB991958.

2. Connect scan tool MB991958 to the data link connector.

3. Set the timing light to the terminal No. 3 power supply line(white-red) of the ignition coil No. 1.

4. Start the engine and run it at idle.

5. Check that the idle speed is approximately 650 r/min.

6. Select scan tool MB991958 actuator test "item number 11".

7. Check that basic ignition timing is within the standard value.

Standard value: 5 BTDC 3

8. If the basic ignition timing is not within the standard value(Refer to GROUP 13B, Multiport Fuel Injection (MFI)Diagnosis Symptom Chart P.13B-56).

CAUTION

If the actuator test is not canceled, the forced drive will

continue for 27 minutes. Driving in this state could lead to

engine failure.

9. Cancel the setting mode of the scan tool MB991958.

10.Check that the actual ignition timing is at the standard value.

Standard value: Approximately 10 BTDC

NOTE: The ignition timing fluctuates about 7, even under

normal operating condition.

NOTE: It is automatically further advanced by about 5

from 10Before Top Dead Center at higher altitudes.

NOTE: Wait till approximately 1 minute passes after the

engine started, and check the ignition timing when the

engine stabilized.

11.Remove the timing light.

AC608435

Data link connector

MB991827

MB991824

MB991910

AB

AK604618

321 321

AB

No. 1 ignition coil

Equipment side connector

Power supply line(terminal No. 3)
http://gr00001300a-13b.pdf/http://gr00001300a-13b.pdf/


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ON-VEHICLE SERVICE

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CAUTION




12.Disconnect scan tool MB991958 from the data linkconnector.

CURB IDLE SPEED CHECKM1111003502757




NOTE: On vehicles for Canada, the headlight, taillight, etc.remain lit even when the lighting switch is in "OFF" position

but this is no problem for checks.

CAUTION





AC608435

Data link connector

MB991827

MB991824

MB991910

AB


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ON-VEHICLE SERVICE

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3. Set the timing light to the terminal No. 3 power supply line(white-red) of the ignition coil No. 1.

4. Start the engine.

5. Run the engine at idle for 2 minutes.

6. Check the actual ignition timing is at the standard value.

Standard value: Approximately 10 BTDC

NOTE: The ignition timing fluctuates about 7, even undernormal operating condition.

NOTE: It is automatically further advanced by about 5from

10Before Top Dead Center at higher altitudes.

NOTE: Wait till approximately 1 minute passes after the

engine started, and check the ignition timing when the

engine stabilized.

7. Check the idle speed. Select item number 2 and take areading of the idle speed.

Curb idle speed: 650 100 r/min

NOTE: The idle speed is controlled automatically by the idle

air control system.

8. If the idle speed is outside the standard value (Refer toGROUP 13B, Multiport Fuel Injection (MFI) Diagnosis Symptom Chart P.13B-56).

9. Remove the timing light.

CAUTION




10.Disconnect scan tool MB991958 from the data linkconnector.

IDLE MIXTURE CHECKM1111002102013



1. Before inspection, set the vehicle in the following condition: Engine coolant temperature: 80 95C (176 203F) Lights and all accessories: OFF

Transaxle: Neutral (P range on vehicles with CVT)NOTE: On vehicles for Canada, the headlight, taillight, etc.

remain lit even when the lighting switch is in "OFF" position


AK604618

321 321

AB

No. 1 ignition coil

Equipment side connector

Power supply line(terminal No. 3)


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ON-VEHICLE SERVICE

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COMPRESSION PRESSURE CHECKM1111002603334



1. Before inspection, check that the engine oil, starter andbattery are normal. Also, set the vehicle in the followingcondition:

Engine coolant temperature: 80 95C (176 203F) Lights and all accessories: OFF Transaxle: Neutral (P range on vehicles with CVT)




2. Turn the ignition switch to the "LOCK" (OFF) position.

3. Disconnect the connector of the ignition coil, and then

remove all the ignition coils and the spark plugs.4. Disconnect the all of the injector connectors.

WARNING

Keep your distance from the spark plug hole whencranking. Oil, fuel, etc., may spray out from the spark

plug hole and may cause serious injury.

5. Cover the spark plug hole with a shop towel etc., after theengine has been cranked, check that no foreign material isadhering to the shop towel.

6. Set compression gauge to one of the spark plug holes.7. Crank the engine with the throttle valve fully open and

measure the compression pressure.

Standard value (at engine speed of 200 r/min): 1,440

kPa (208.8 psi)

Limit (at engine speed of 200 r/min): Minimum 1,000

kPa (145.0 psi)

8. Measure the compression pressure for all the cylinders, andcheck that the pressure differences of the cylinders arebelow the limit.

Limit: Maximum 100 kPa (14.5 psi)

9. If there is a cylinder with compression or a compressiondifference that is outside the limit, pour a small amount ofengine oil through the spark plug hole, and repeat theoperations in steps from 6 to 8.

(1) If the compression increases after oil is added, the causeof the malfunction is a worn or damaged piston ringand/or cylinder inner surface.

(2) If the compression does not rise after oil is added, thecause is a burnt or defective valve seat, or pressure isleaking from the gasket.

10.Connect the all of the injector connector.

AK502603AE

Injectorconnectors

AK502604AE

Compression gauge


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ON-VEHICLE SERVICE

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11.Install the spark plugs and ignition coils.

12.Use the scan tool MB991958 to erase the diagnosis codes.

NOTE: This will erase the diagnosis code resulting from the

injector connectors being disconnected.

13.Select "Mode $0A" from "Special Function" of Scan toolMB991958. Check whether the permanent-DTC (PDTC) isstored or not. If stored, clear the PDTC. (Refer to GROUP13B Multiport Fuel Injection (MFI) Multiport Fuel Injection (MFI) Diagnosis DiagnosticFunction P.13B-12)

MANIFOLD VACUUM CHECKM1111002702167







AC608435

Data link connector

MB991827

MB991824

MB991910

AB


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ON-VEHICLE SERVICE

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CAUTION





3. Disconnect the ventilation hose from the positive crankcaseventilation (PCV) valve, and then connect a vacuum gaugeto the ventilation hose. Plug the PCV valve.

4. Start the engine and check that idle speed is approximately650 r/min.

5. Check the intake manifold vacuum.

Limit: Minimum 60 kPa (17.8 in Hg)

6. Turn off the ignition switch.7. Remove the vacuum gauge and then connect the ventilation

hose to the PCV valve.

CAUTION




8. Disconnect scan tool MB991958 from the data linkconnector.

AC608435

Data link connector

MB991827

MB991824

MB991910

AB

AK502601AE

Plug

PCV valve

Vacuum gauge


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CRANKSHAFT PULLEY

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CRANKSHAFT PULLEYREMOVAL AND INSTALLATION

M1112001602955


MB992278: Belt Tension Release Wrench MB990767: Front Hub and Flange Yoke Holder MD998719: Pin

Pre-removal Operation

Engine Room Under Cover Front B and Engine RoomSide Cover (RH) Removal (Refer to GROUP 51, UnderCover P.51-20.)

Post-installation Operation

Drive Belt Tension Check (Refer to P.11C-8.) Engine Room Under Cover Front B and Engine Room

Side Cover (RH) Installation (Refer to GROUP 51, Under

Cover P.51-20.)

AC611683AC

210 Nm155 ft-lb

2

3

4

51

12 2 Nm102 22 in-lb

(Engine oil)

Removal steps

1. Radiator condenser tank assembly >>B>A>A>A


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CRANKSHAFT PULLEY

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REMOVAL SERVICE POINTS.

RADIATOR CONDENSER TANK ASSEM-

BLY REMOVALRemove the radiator condenser tank assembly mounting bolt,and move the radiator condenser tank assembly to a placewhere it does not interfere with the drive belt removal and

installation..

DRIVE BELT REMOVALSince the serpentine drive system with the auto-tensioner isused, the following operations will be required.

CAUTION

To reuse the drive belt, draw an arrow indicating the rotat-

ing direction on the back of the belt using chalk to install

the same direction.

1. Rotate the pulley bolt of the auto-tensioner counterclockwisewith an special tool MB992278 and insert the L-shaped

hexagon wrench into the auto-tensioner hole to fix theauto-tensioner.

2. Remove the drive belt.

.

CRANKSHAFT PULLEY CENTER

BOLT/CRANKSHAFT PULLEY

WASHER/CRANKSHAFT PULLEY REMOVAL1. Hold the crankshaft pulley with special tools MB990767 and

MD998719.

2. Loosen the crankshaft pulley center bolt and remove thecrankshaft pulley center bolt, crankshaft pulley washer andcrankshaft pulley.

AC804028AF

Auto-tensioner

MB992278

AC511067AC

Auto-tensioner

Pulley bolt

L-shapedhexagonwrench

AC506738 ACMB990767

MD998719

Crankshaft pulley


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CRANKSHAFT PULLEY

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INSTALLATION SERVICE POINTS.

>>A


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CRANKSHAFT PULLEY

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>>B


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CRANKSHAFT PULLEY

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2. Set an special tool MB992278 to the pulley bolt of theauto-tensioner. Then, rotate the auto-tensionercounterclockwise and remove the L-shaped hexagonwrench fixing the auto-tensioner.

3. Apply tension to the drive belt while slowly turning theauto-tensioner clockwise.

AC804028AF

Auto-tensioner

MB992278

AC511067AC

Auto-tensioner

Pulley bolt

L-shapedhexagonwrench


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CAMSHAFT

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CAMSHAFTREMOVAL AND INSTALLATION

M1112007800906


Engine Room Under Cover Front A, B and Engine RoomSide Cover (RH) Removal (Refer to GROUP 51, UnderCover P.51-20.)

Air Cleaner Assembly Removal (Refer to GROUP 15, AirCleaner P.15-10.)

Strut Tower Bar Removal (Refer to GROUP 42A, StrutTower Bar P.42A-15.)

Ignition Coil Removal (Refer to GROUP 16, Ignition Sys-tem Ignition Coil P.16-51.)


Ignition Coil Installation (Refer to GROUP 16, IgnitionSystem Ignition Coil P.16-51.)

Strut Tower Bar Installation (Refer to GROUP 42A, Strut

Tower Bar P.42A-15.) Air Cleaner Assembly Installation (Refer to GROUP 15,

Air Cleaner P.15-10.) Engine Room Under Cover Front A, B and Engine Room

Side Cover (RH) Installation (Refer to GROUP 51, UnderCover P.51-20.)

AC708410

2

20

15

14

11

7

17

4

3

AF

59 5 Nm44 3 ft-lb

5

16

3.0 0.5 Nm27 4 in-lb

27

28

26

19

9

1

12

1321

22

2325

24

30

3129 N

32N

8

10

18

6N

Apply engine oil to all

moving parts before

installation.

(Engine oil)

(Engine oil)

3.0 1.0 Nm27 8 in-lb

to5.5 0.5 Nm49 4 in-lb

12 1 Nm107 8 in-lb

17 3 Nm13 2 ft-lb

to30 2 Nm22 1 ft-lb

10 2 Nm89 17 in-lb

10 2 Nm89 17 in-lb

10 2 Nm89 17 in-lb

13 1 Nm115 8 in-lb

25 4 Nm18 3 ft-lb

12 1 Nm107 8 in-lb
http://gr00003700-51.pdf/http://gr00001600-15.pdf/http://gr00002400-42a.pdf/http://gr00001700-16.pdf/http://gr00001700-16.pdf/http://gr00002400-42a.pdf/http://gr00001600-15.pdf/http://gr00003700-51.pdf/http://gr00003700-51.pdf/http://gr00001600-15.pdf/http://gr00002400-42a.pdf/http://gr00001700-16.pdf/http://gr00001700-16.pdf/http://gr00002400-42a.pdf/http://gr00001600-15.pdf/http://gr00003700-51.pdf/


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CAMSHAFT

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MB992103: Chain Tension Release Bar


ROCKER COVER ASSEMBLY REMOVALLoosen the rocker cover assembly mounting bolts in the orderof number shown in the figure, and remove the rocker coverassembly.

.

Camshaft removal steps

1. Engine upper cover2. Breather hose connection3. PCV hose connection4. Control wiring harness

connection >>G>F>E>D>D>D>D>E>B>B>E>D>D>D>D>C>B>B>A>A>A>A


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CAMSHAFT

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NUMBER 1 CYLINDER COMPRESSION

TOP DEAD CENTER SETTING

CAUTION

Never turn the crankshaft counterclockwise.

1. Turn the crankshaft clockwise so that the camshaft sprockettiming marks become horizontal to the cylinder head upper

surface, and set the number 1 cylinder to the top deadcenter of compression. At this time, check that thecrankshaft pulley timing mark is in the 0-degree angleposition of the ignition timing indicator of the timing chaincase assembly.

2. Put paint marks on both the camshaft sprocket and timingchain at the position of camshaft sprocket timing chainmating mark (circular hole.)

.

CAMSHAFT AND CAMSHAFT SPROCKET

ASSEMBLY (EXHAUST SIDE) REMOVAL

PREPARATORY OPERATION1. Insert a precision flat-tipped screwdriver through the service

hole of the timing chain case assembly, press up the timingchain tensioner ratchet to unlock, and keep the timing chaintensioner with that state.

NOTE: Lightly press down the tail end of the precision

flat-tipped screwdriver to press up the tip of the precision

flat-tipped screwdriver inserted to the timing chain tensioner

to unlock.

AC506744

Paintmarkings

Camshaft sprockettiming marks

Timing chainmating mark

Timing chainmating mark

AC

Cylinder head upper surface

AC509155AC

Section A-A

A

A

Precision flat-tippedscrewdriver

Service hole

Crankshaft pulley

Service holeRatchet

Precision flat-tipped screwdriver

Ratchetrelease hole

Timing chaintensioner

Ratchet

Ratchetrelease hole

Timing chain tensioner

construction diagram


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CAMSHAFT

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CAUTION

When inserting special tool MB992103 into the timing

chain case assembly inside, pay attention to the posi-

tion of the timing chain to avoid damage to the timing

chain and timing chain tension side guide. Do not

insert the special tool MB992103 beyond its insertion

guideline.

If unlocking the timing chain tensioner is insufficient,the special tool MB992103 cannot be inserted to the

insertion guideline. Do not insert the special tool

MB992103 forcibly, follow Step 1 again to unlock the

timing chain tensioner and insert the special tool

MB992103.

AC507118AC

Timing chain

MB992103

Insertion standard line


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CAMSHAFT

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2. With the timing chain tensioner unlocked, insert special toolMB992103 inside the timing chain case assembly along thetension side of the timing chain until the insertion guide linealigns with the upper surface of the timing chain caseassembly (Figure A.)

NOTE: With the timing chain tensioner unlocked, insert the

special tool MB992103 along the tension side of the timing

chain, according to the special tool MB992103 top shape.The special tool MB992103 can be inserted smoothly to the

position where the special tool MB992103 insertion guide

line aligns with the timing chain case assembly top surface

(Figure B), and the spread timing chain tension side guide

can be held (Figure C.)

3. With the special tool MB992103 inserted up to the insertionguide line, press the special tool MB992103 against theintake side camshaft sprocket and spread and hold thetiming chain tension side guide.

4. Remove the flat-tipped precision screwdriver unlocking the

timing chain tensioner.CAUTION

The timing chain may snag on by other parts. After sag-

ging the timing chain, never rotate the crankshaft.

5. With the timing chain tension side guide spread, hook thespecial tool MB992103 over the hexagon part of thecamshaft on the exhaust side, and turn the camshaftclockwise to apply slack to the timing chain between thecamshaft sprockets.

.

AC508123

AC509159AB

MB992103

MB992103


Timing chain tension

side guide

Timing chaintensionside guide

Camshaftsprocket(intake side)

Valve timing chain(tension side)

A

B

C

AC506748 AC

MB992103

Timing chain

Hexagonpart ofexhaustcamshaft


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CAMSHAFT

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FRONT CAMSHAFT BEARING CAP

REMOVALLoosen the front camshaft bearing cap mounting bolts in theorder of number shown in the figure, and remove the front cam-shaft bearing cap.

.

OIL FEEDING CAMSHAFT BEARING

CAP/CAMSHAFT BEARING CAP/THRUST

CAMSHAFT BEARING CAP REMOVAL

CAUTION

When the camshaft bearing cap mounting bolts are loos-

ened at once, the mounting bolts jump out by the spring

force and the threads are damaged. Always loosen the

mounting bolts in four or five steps.

Loosen the camshaft bearing cap mounting bolts in the order ofnumber shown in the figure in four or five steps, and removethe camshaft bearing caps.

.

AC506745AG

1

2

3

4

Engine front

Front camshaft

bearing cap

AC506746AC

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

Engine front

Camshaft bearing cap



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CAMSHAFT

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CAMSHAFT AND CAMSHAFT SPROCKET

ASSEMBLY (EXHAUST SIDE) REMOVAL1. Raise slightly the transaxle side of the camshaft and

camshaft sprocket assembly (exhaust side) by using theslack of the timing chain, and remove from the cam bearing.

2. Remove the timing chain from the camshaft and camshaftsprocket assembly (exhaust side) toward the timing chaincase assembly, and remove the camshaft and camshaftsprocket assembly (exhaust side) toward the transaxle.

3. Remove special tool MB992103 inserted into the timingchain case assembly.

CAUTION

The timing chain may snag on other parts. After removing

the camshaft and camshaft sprocket assembly, never

rotate the crankshaft.

4. After removing the camshaft and camshaft sprocketassembly (exhaust side), hang up the timing chain with arope to prevent the timing chain from falling into the timingchain case assembly.

.

AC508124AD

Camshaft and camshaftsprocket assembly

AC506749AC

MB992103

Timing chain

Camshaft andcamshaft sprocket

assembly

AC509403AD

Rope Timing chain


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CAMSHAFT

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CAMSHAFT SPROCKET/CAMSHAFT

REMOVALHold the hexagon part of the camshaft with a monkey wrench.Loosen the camshaft sprocket mounting bolt and remove thecamshaft sprocket from the camshaft.

.

POWER STEERING OIL PUMP ASSEMBLY

REMOVAL

1. With the hose installed, remove the power steering oil pumpassembly from the bracket.

2. Tie the removed power steering oil pump assembly with astring at a position where it will not interfere with the removaland installation of oil feed control valve.

.

OIL FEEDER CONTROL VALVE REMOVAL

CAUTION

After removal of the oil feeder control valve, be careful to

prevent dust from getting into the oil passage in the cylin-

der head.


>>A>B


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CAMSHAFT

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2. Apply an adequate and minimum amount of engine oil to thecamshaft and camshaft sprocket as shown in the figure.

3. Install the camshaft sprocket to the camshaft.

4. Apply an adequate and minimum amount of engine oil to thecamshaft sprocket mounting bolt.

5. Tighten the camshaft sprocket mounting bolt to the specifiedtorque.

Tightening torque: 59 5 N m (44 3 ft-lb)

.

>>C>D


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CAMSHAFT

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>>E


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CAMSHAFT

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2. In the same manner as removal, insert the precisionflat-tipped screwdriver through the service hole of the timingchain case assembly, press up the ratchet of timing chaintensioner to unlock, and hold the unlocked timing chaintensioner.

NOTE: Lightly press down the tail end of the precision

flat-tipped screwdriver to press up the tip of the precision

flat-tipped screwdriver inserted to the timing chain tensionerto unlock.

AC509155AC

Section A-A

A

A

Precision flat-tippedscrewdriver

Service hole

Crankshaft pulley

Service holeRatchet

Precision flat-tipped screwdriver

Ratchetrelease hole


Ratchet

Ratchet

release hole

Timing chain tensionerconstruction diagram


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CAMSHAFT

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CAUTION

When inserting special tool MB992103 into the timing

chain case assembly, pay attention to the position of

the timing chain to avoid damage to the timing chain

and timing chain tension side guide. Do not insert the

special tool MB992103 beyond its insertion guideline.

If unlocking the timing chain tensioner is insufficient,

the special tool MB992103 cannot be inserted to theinsertion guideline. Do not insert the special tool

MB992103 forcibly, follow Step 2 again to unlock the

timing chain tensioner and insert the special tool

MB992103.

AC507118AC

Timing chain

MB992103

Insertion standard line


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CAMSHAFT

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3. With the timing chain tensioner unlocked, insert special toolMB992103 inside the timing chain case assembly along thetension side of the timing chain until the insertion guide linealigns with the upper surface of the timing chain caseassembly (Figure A.)

NOTE: With the timing chain tensioner unlocked, insert the

special tool MB992103 along the tension side of the timing

chain, according to the special tool MB992103 top shape.The special tool MB992103 can be inserted smoothly to the

position where the special tool MB992103 insertion guide-

line aligns with the timing chain case assembly top surface,

and the spread timing chain tension side guide can be hold.

4. With the special tool inserted up to the insertion guide line,press the special tool MB992103 against the intake sidecamshaft sprocket (Figure B) and spread and hold thetiming chain tension side guide (Figure C.)

5. Remove the flat-tipped precision screwdriver unlocking thetiming chain tensioner.

6. Pull up the camshaft and camshaft sprocket assembly(exhaust side) mounting area of the timing chain (Figure D)to provide allowance for easy installation of the camshaftand camshaft sprocket assembly (exhaust side) to thetiming chain.

CAUTION

When installing the camshaft and camshaft sprocket

assembly (exhaust side), be careful not to let the camshaft

bearing which is installed to the front cam bearing deviate

from its position.

7. Align the exhaust side paint mark of the timing chain whichwas put at removal with the paint mark of the exhaust sidecamshaft sprocket, and install the timing chain to thecamshaft sprocket.

8. Install the camshaft and camshaft sprocket assembly(exhaust side) to the cylinder head.

9. Remove the special tool MB992103 inserted into the timingchain case assembly inside.

.

AC509177

AC508125

AD

MB992103

MB992103Timing chaintensioner

Timing chain

tension side guide

Timing chaintensionside guide

Timing chain(tension side)

Camshaftsprocket(intake side)

Timing chain(exhaust camshaft andcamshaft sprocketassembly side)

A B

C

D

AC506752 AB

Paint markings(exhaust side)


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VALVE STEM SEAL

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VALVE STEM SEALREMOVAL AND INSTALLATION

M1112008100966

CAUTION

*Remove and assemble the marked parts in each cylinder unit.



Engine Oil Draining (Refer to GROUP 12, On-vehicle Ser-vice Engine Oil Replacement P.12-5.)

Rocker Cover Assembly Removal (Refer to P.11C-24.) Engine Oil Pan Removal (Refer to P.11C-46.) Timing Chain Removal (Refer to P.11C-64.)


Timing Chain Installation (Refer to P.11C-64.) Engine Oil Pan Installation (Refer to P.11C-46.) Valve Clearance Check (Refer to P.11C-11.) Rocker Cover Assembly Installation (Refer to P.11C-24.) Engine Oil Refilling (Refer to GROUP 12, On-vehicle Ser-

vice Engine Oil Replacement P.12-5.) Engine Room Under Cover Front A, B and Engine Room


AC709946

6

3 11

AD

7

12

13

1

4

5

109

14 N

N

2

8

15*

16*

17*18*

19*

15*

16* 17*

18*

19*

25 5 Nm18 3 ft-ib

Apply engine oil to allmoving parts before

installation.

12 1 Nm107 8 in-lb

17 3 Nm

13 2 ft-lbto

30 2 Nm

22 1 ft-lb

12 1 Nm107 8 in-lb

Removal steps >>F>E>D>D>D>D>E>E>D>D>D>D


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VALVE STEM SEAL

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MD998772: Valve Spring Compressor MB992089: Retainer Holder C MB992090: Retainer Holder Attachment

MB992085: Valve Stem Seal Pliers MD998737: Valve Stem Seal Installer



REMOVAL

CAUTION

Be careful not to drop the camshaft bearing.

Loosen the front camshaft bearing cap mounting bolts in theorder of number shown in the figure, and remove the front cam-shaft bearing cap.

.

13. Camshaft and camshaft sprocketassembly (intake side)

14. Spark plug >>C>B>A


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VALVE STEM SEAL

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CAUTION



force and the threads are damaged. Always loosen themounting bolts in four or five steps.

Loosen the camshaft bearing caps mounting bolts in the orderof number shown in the figure in four or five steps, and removethe camshaft bearing caps.

.

VALVE TAPPET REMOVAL

CAUTION

Do not use pliers or other tools to remove the valve tap-

pets. Always remove them by hand.

When reusing the removed valve tappet, it has to be

installed in the same position as before. Be sure to put

a tab that shows the original installation position on the

valve tappet when storing it.

Remove all of the valve tappets by hand.

.

AC506746 AC

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

Engine front



AC509270 AC

Valve tappet


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VALVE STEM SEAL

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VALVE SPRING RETAINER LOCK

REMOVAL1. Screw in special tool MB992090 to special tool MD998772

and assemble special tool MB992089.

CAUTION

When removing the valve spring retainer lock, leave the

piston of the cylinder in the TDC (Top Dead Center) posi-tion. The valve may fall into the cylinder if the piston is not

properly in the TDC position.

2. Install special tool MD998772 (with special tools MB992090and MB992089 attached) to the cylinder head and compressthe valve spring. Then, remove the valve spring retainerlock.

.

VALVE STEM SEAL REMOVALUse special tool MB992085 to grip the base of the stem seal(where the outside diameter is larger) securely, and remove itby twisting it to the left and right.

AC509271AC

MD998772

MB992090

MB992089

AC608112 ABValve stem seal

MB992085


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VALVE STEM SEAL

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>>B>C


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VALVE STEM SEAL

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>>D


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VALVE STEM SEAL

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>>E>F


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OIL PAN

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OIL PANREMOVAL AND INSTALLATION

M1112002802769


MD998727: Oil Pan FIPG Cutter




Drive Belt Removal (Refer to P.11C-19.)


Drive Belt Installation (Refer to P.11C-19.) Engine Oil Refilling (Refer to GROUP 12, On-vehicle Ser-

vice Engine Oil Replacement P.12-5.)

Engine Room Under Cover Front A, B and Engine RoomSide Cover (RH) Installation (Refer to GROUP 51, UnderCover P.51-20.)

AC803678

6

5

7

1

4

39 5 Nm29 3 ft-lb

10 2 Nm89 17 in-lb

29 2 Nm22 1 ft-lb

23 6 Nm17 4 ft-lb

23 6 Nm17 4 ft-lb

N

AB

323 6 Nm17 4 ft-lb

23 6 Nm17 4 ft-lb

2

Removal steps

1. A/C compressor and clutchconnector connection

>>C>B>A


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OIL PAN

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A/C COMPRESSOR AND CLUTCH ASSEM-

BLY REMOVAL

1. Remove the A/C compressor and clutch assembly togetherwith the hose from the bracket.

2. Tie the removed A/C compressor and clutch assembly witha string at a position where they will not interfere with theremoval and installation of engine oil pan.

.

ENGINE OIL PAN REMOVAL

1. Remove the engine oil pan mounting bolts.

CAUTION

Do not forcibly drive in special tool MD998727 to avoid

damage to the engine oil pan seal surface of cylinder block

assembly.

2. Insert special tool MD998727 from the engine oil pan

removal groove of the cylinder block assembly.3. Lightly tap the special tool MD998727 with a hammer toslide the engine oil pan seal surface, cut off the liquidgasket, and remove the engine oil pan.

AC506757AC

Engine oil pan

Crankshaft pulley

AC506758AC

Engine oil filter

Engine oil pan

AC102324AB

MD998727 MD998727


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OIL PAN

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>>A>B>C


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CRANKSHAFT OIL SEAL

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CRANKSHAFT OIL SEALREMOVAL AND INSTALLATION

M1112003103380


MB991883: Flywheel Stopper MD998718: Crankshaft Rear Oil Seal Installer MB991448: Bush Remover And Installer Base

AC807650

1

2

3

4

5

6

7

40 Nm30 ft-lb

N

N

AE

130 Nm96 ft-lb

to

40 Nm30 ft-lb

130 Nm96 ft-lb

to

17 2, 4

Engine oil Seating surface: Engine oilThread: Three bond 1324or exact equivalent

Crankshaft front oil seal removal

steps

Crankshaft pulley (Refer to

P.11C-19)>>C>B>B>A>B>B>B>A


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CRANKSHAFT OIL SEAL

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REMOVAL SERVICE POINT.

FLYWHEEL BOLT /DRIVE PLATE

BOLT REMOVALFix the flywheel assembly using special tool MB991883, andloosen the flywheel bolts Fix the drive plate using special tool MB991883, and loosen the

drive plate bolts


>>A>B


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CRANKSHAFT OIL SEAL

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3. Use special tool MB991883 to secure the drive plate in thesame manner as removal

Use special tool MB991883 to secure the flywheel assemblyin the same manner as removal

4. Apply a small amount of engine oil to the screw holes of thecrankshaft and the bearing surface of the drive plate bolts

Apply a small amount of engine oil to the screw holes of thecrankshaft and the bearing surface of the flywheel bolts

5. Apply specified sealant to the drive plate bolts orflywheel bolts threads.

Specified sealant: Three bond 1324 or exact equiva-

lent

6. Tighten the drive plate bolts or flywheel bolts to the specified torque in the order shown in the illustration.

Tightening torque: 40 N m (30 ft-lb)

7. Tighten the drive plate bolts or flywheel bolts to the specified torque again in the order shown in theillustration.


.

>>C


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CYLINDER HEAD GASKET

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CYLINDER HEAD GASKETREMOVAL AND INSTALLATION

M1112004004130


Fuel Line Pressure Reduction (Refer to GROUP 13B,On-vehicle Service How to Reduce Pressurized FuelLines P.13B-1000.)


Engine Coolant Draining (Refer to GROUP 14, On-vehicleService Engine Coolant Replacement P.14-26.)

Air Cleaner Assembly Removal (Refer to GROUP 15, AirCleaner P.15-10.)

Ignition Coil Removal (Refer to GROUP 16, Ignition Sys-tem Ignition Coil P.16-51.)

Exhaust Manifold Removal (Refer to GROUP 15, ExhaustManifold P.15-26.)

Throttle Body Assembly Removal (Refer to GROUP 13B,Throttle Body Assembly P.13B-1020.)

EGR Valve and EGR Valve Stay Removal (Refer toGROUP 17, EGR Valve P.17-106.)

Water Pump Removal (Refer to GROUP 14, Water PumpP.14-40.)


Water Pump Installation (Refer to GROUP 14, WaterPump P.14-40.)

EGR Valve and EGR Valve Stay Installation (Refer to

GROUP 17, EGR Valve P.17-106.) Throttle Body Assembly Installation (Refer to GROUP

13B, Throttle Body Assembly P.13B-1020.) Exhaust Manifold Installation (Refer to GROUP 15,

Exhaust Manifold P.15-26.) Ignition Coil Installation (Refer to GROUP 16, Ignition

System Ignition Coil P.16-51.) Air Cleaner Assembly Installation (Refer to GROUP 15,

Air Cleaner P.15-10.) Engine Coolant Refilling (Refer to GROUP 14, On-vehicle

Service Engine Coolant Replacement P.14-26.) Fuel Leak Check Engine Room Under Cover Front A, B and Engine Room

http://gr00001300d-13b.pdf/http://gr00003700-51.pdf/http://gr00001500-14.pdf/http://gr00001600-15.pdf/http://gr00001700-16.pdf/http://gr00001600-15.pdf/http://gr00001300d-13b.pdf/http://gr00001900-17.pdf/http://gr00001500-14.pdf/http://gr00001500-14.pdf/http://gr00001900-17.pdf/http://gr00001300d-13b.pdf/http://gr00001600-15.pdf/http://gr00001700-16.pdf/http://gr00001600-15.pdf/http://gr00001500-14.pdf/http://gr00003700-51.pdf/http://gr00003700-51.pdf/http://gr00001500-14.pdf/http://gr00001600-15.pdf/http://gr00001700-16.pdf/http://gr00001600-15.pdf/http://gr00001300d-13b.pdf/http://gr00001900-17.pdf/http://gr00001500-14.pdf/http://gr00001500-14.pdf/http://gr00001900-17.pdf/http://gr00001300d-13b.pdf/http://gr00001600-15.pdf/http://gr00001700-16.pdf/http://gr00001600-15.pdf/http://gr00001500-14.pdf/http://gr00003700-51.pdf/http://gr00001300d-13b.pdf/


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AC702470

1

9

8

6

4

2

N

AC

37N

10

11

12

13

145

24 3 Nm18 2 ft-lb

20 2 Nm15 1 ft-lb

Removal steps

1. Control wiring harness connection >>H>H>G>F


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MB991454: Engine Hanger Balancer MB991895: Engine Hanger MB991928: Engine Hanger

AC704318AF

26

23

25

21

N

20

17

15

18

19

N

24 N16

22


moving parts beforeinstallation.

(Engine oil)

(Engine oil)

12 1 Nm107 8 in-lb

17 3 Nm13 2 ft-lb

30 2 Nm22 1ft-lb

to

35 2 Nm26 1 ft-lb

12 1 Nm107 8 in-lb

35 2 Nm26 1 ft-lb

to +90 to +90

to +90 to +90

Removal steps

Valve timing chain (Refer to

P.11C-64) >>E>C>D>D>D>D>C>C>B>B>A>A


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RADIATOR UPPER HOSE/RADIATOR

LOWER HOSE DISCONNECTIONMake mating marks on the radiator hose and the hose clampas shown to install them in the original position. Then, removethem.

.

FUEL HIGH-PRESSURE HOSE

DISCONNECTION1. Remove the stopper of the fuel high-pressure hose.

2. Raise the retainer of the fuel high-pressure hose and pull outthe fuel high-pressure hose in the direction shown in thefigure.

NOTE: If the retainer is released, install it securely after

removing the fuel high-pressure hose.

.


REMOVAL1. Temporarily install the engine oil pan which was removed at

the timing chain removal (Refer to P.11C-46.)

CAUTION

When supporting the engine and transaxle assembly with

a garage jack, be careful not to deform the engine oil pan.

2. Place a garage jack against the engine oil pan with a pieceof wood in between to support the engine and transaxleassembly.

AC606081

Mating marks

AH

AC301860AC

Stopper

AC301861AC

Retainer


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3. Remove special tool MB991454, MB991928 or MB991895which was installed for supporting the engine and transaxleassembly when the timing chain was removed.

CAUTION

Be careful not to drop the camshaft bearing.

4. Loosen the front camshaft bearing cap mounting bolts in theorder of number shown in the figure, and remove the frontcamshaft bearing cap.

.

AC611558AB

MB991454

MB991928

AC611557AB

MB991454

MB991895

AC506745AG

1

2

3

4

Engine front

Front camshaft

bearing cap


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CAUTION



force and the threads are damaged. Always loosen themounting bolts in four or five steps.

Loosen the camshaft bearing cap mounting bolts in the order ofnumber shown in the figure in four or five steps, and removethe camshaft bearing caps.

.

CYLINDER HEAD BOLT/CYLINDER HEAD

BOLT ASSEMBLY REMOVALLoosen and remove the cylinder head bolts in two or threesteps in the order of number shown in the figure.

AC506746 AC

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

Engine front



AC506767AD

1

23

4

5

67

8

9

10

Engine front


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>>A


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>>B


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>>C


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>>D>E


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3. Install special tool MB991454, MB991928 or MB991895which was installed for supporting the engine and transaxleassembly when the timing chain was removed (Refer to

P.11C-64.)

4. Remove the garage jack which supports the engine andtransaxle assembly.

5. Remove the engine oil pan installed temporarily.

.

>>F


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>>G>H


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TIMING CHAIN

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TIMING CHAINREMOVAL AND INSTALLATION

M1112007201286




Rocker Cover Assembly Removal (Refer to P.11C-24.) Engine Oil Pan Removal (Refer to P.11C-46.)


Engine Oil Pan Installation (Refer to P.11C-46.) Rocker Cover Assembly Installation (Refer to P.11C-24.) Engine Oil Refilling (Refer to GROUP 12, On-vehicle Ser-

vice Engine Oil Replacement P.12-5.) Engine Room Under Cover Front A, B and Engine Room


AC700425AD

1

24 4 Nm18 3 ft-lb

2 3

5

7

9

10

11

12

13

45 5 Nm34 3 ft-lb

48 7 Nm36 5 ft-lb

22 4 Nm16 3 ft-lb

9.0 1.0 Nm80 9 in-lb

23 2 Nm17 1 ft-lb

10 2 Nm89 17 in-lb

6 N


moving parts before

installation.

48 7 Nm36 5 ft-lb

10 2 Nm89 17 in-lb

10 2 Nm89 17 in-lb

10 2 Nm89 17 in-lb

10 2 Nm89 17 in-lb

10 2 Nm89 17 in-lb

4

25 4 Nm18 3 ft-lb

13 2 Nm111 2 in-lb

8 N

Removal steps

> Crankshaft pulley (Refer toP.11C-19)>>E>D>C>B>A


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TIMING CHAIN

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MB991454: Engine Hanger Balancer MB991895: Engine Hanger

MB991928: Engine Hanger MB991448: Bush Remover and Installer Base


CRANKSHAFT PULLEY REMOVAL

When removing the crankshaft pulley, slightly loosen the waterpump pulley mounting bolts before removal of the drive belt.

.


REMOVAL

1. With the hose installed, remove the power steering oil pumpassembly from the bracket.

2. Tie the removed power steering oil pump assembly with astring at a position where it will not interfere with the removaland installation of timing chain.

.

ENGINE AND TRANSAXLE ASSEMBLY

HOLDINGInstall a special tool for holding the engine and transaxleassembly.

1.

(1) Assemble the special tool MB991928. Set the followingparts on the base hanger.

Slide bracket (HI) Foot x 4 (standard) (MB991932) Joint x 2 (90) (MB991930)(2) Set the foot of the special tool as shown in the figure.

NOTE: Slide the slide bracket (HI) to adjust the engine

hanger balance.

(3) Mount special tool MB991454 to the power steering oilpump bracket and engine hanger, and set it to specialtool MB991928 to support the engine and transaxleassembly.

AC611565AB

MB991932

MB991932

MB991930

AC611558AB

MB991454

MB991928


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TIMING CHAIN

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2. (1) Set the foot of special tool MB991895 as shown in the

figure.

NOTE: Slide the foot to adjust the engine hanger bal-

ance.

(2) Mount special tool MB991454 to the power steering oilpump bracket and the engine hanger, and set it to specialtool MB991895 to support the engine and transaxleassembly.

.

TIMING CHAIN CASE ASSEMBLY

REMOVAL

CAUTION

If the adhesive strength of sealant on the timing chain case

assembly is so strong that the boss may be damaged by

peeling off, do not peel it off forcibly.

1. After removing the timing chain case assembly mountingbolts, slightly pry the boss of the timing chain case assemblyshown in the figure using a flat-tipped screwdriver, andremove the timing chain case assembly from the cylinderhead and cylinder block.

2. If the sealant cannot be peeled off easily, insert a wooden

hammer shank into the timing chain case assembly insideas shown in the figure, pry slightly, and remove the timingchain case assembly from the cylinder head and cylinderblock.

.

AC611564AB

MB991895

AC611557AB

MB991454

MB991895

AC700719AC

Boss

Timing chaincase assembly

AC506771AC

Hammer

Timing chaincase assembly


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TIMING CHAIN

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TIMING CHAIN TENSIONER REMOVAL

1. Temporarily install the crankshaft pulley to the crankshaft.

CAUTION


2. Turn the crankshaft clockwise to align the sprocket timingmarks as shown in the figure and set the number 1 cylinder

to the top dead center of compression stroke.NOTE: At this time, it is not necessary that the link plate

(orange or blue) of the timing chain always aligns with each

sprocket timing mark.

3. Remove the crankshaft pulley installed temporarily.

4. Using a flat-tipped precision screwdriver, release the ratchetof timing chain tensioner.

5. Compress the plunger of timing chain tensioner and inserthard wire (such as piano wire) or the L-shaped hexagon

wrench [1.5 mm(0.05 inch)] to fix the plunger of the timingchain tensioner.

6. Remove the timing chain tensioner.

AC506772AG

Camshaft sprocket

timing marks

Crankshaft sprocket

timing mark

AC506773AD


Ratchet release holeHard wire orL-shapedhexagonwrench


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TIMING CHAIN

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>>A


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TIMING CHAIN

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>>B>C


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TIMING CHAIN

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.

>>D


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TIMING CHAIN

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6. Insert the bolts to the timing chain case assembly as shown,and tighten them to the specified torque.

.

>>E


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BALANCER TIMING CHAIN, BALANCER SHAFT AND OIL PUMP MODULE

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TIMING CHAIN TENSIONER REMOVAL

CAUTION

Securely install the plunger of the timing chain tensioner.

Otherwise, it may pop out.

1. Press the balancer timing chain against the timing chain

tensioner, compress the plunger of the timing chaintensioner and insert hard wire (piano wire, etc.) or L-shapedhexagon wrench [1.5 mm (0.05 inch)] to fix the plunger ofthe timing chain tensioner.

2. Remove the timing chain tensioner.


>>A


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2. Wipe the dirt on the crankshaft sprocket and the crankshaftusing a rag, and then remove the grease from the portionshown in the illustration.

NOTE: Remove grease to prevent a drop in the coefficient

of friction of the pressing portion caused by adhesion of oil.

3. With the link marks (orange or blue) of balancer timing chainaligned with the timing marks of balancer sprocket andcrankshaft sprocket, install the balancer shaft and oil pumpmodule together with the balancer timing chain andcrankshaft sprocket as one unit to the cylinder block. At thistime, securely bring the balancer shaft and oil pump moduleinto contact with the rudder frame mounting area.

4. Apply an adequate and minimum amount of engine oil to the

threads and bearing surfaces of the balancer shaft and oilpump module mounting bolts.

5. Tighten the balancer shaft and oil pump module mountingbolts to the specified torque in the order of number shown inthe figure.


6. Retighten the balancer shaft and oil pump module mountingbolts to the specified torque in the order of number shown inthe figure.


7. Loosen each balancer shaft and oil pump module mounting

bolts fully in the reverse sequence to that shown.8. Tighten the balancer shaft and oil pump module mounting

bolts again to the specified torque in the order of numbershown in the figure.


AC807896Crankshaft sprocket

Crankshaft

AB

Enginefront

: Wipe clean with a rag.: Wipe clean with a rag and degrease.

AC506780AE

Balancer shaft

sprocket

timing markCrankshaft

sprocket

timing mark

(key slot)

Crankshaft

sprocket

timing mark

Link plate (orange)

Link plate (blue)Balancer shaft

housing

timing mark

AC506784 AB

1

2

3

4

Balancer shaft andoil pump module


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9. After tightening to the specified torque, tighten the balancershaft and oil pump module mounting bolts to 135 degreesangle, using special tool MB991614, in the order of numbershown in the figure.

.

>>B


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BALANCER SHAFT AND OIL PUMP MODULE

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BALANCER SHAFT AND OIL PUMP MODULEREMOVAL AND INSTALLATION

M1112008900230


MB991614: Angle Gauge

Pre-removal and Post-installation Operation

Engine Oil Pan Removal and Installation (Refer toP.11C-46.)

AC509274

20 Nm

15 ft-lb

44 Nm

32 ft-lb

to 0 Nmto to20 Nm

15 ft-lb

to +135

1

(Engine oil)

10 2 Nm89 17 in-lb

AE

Removal steps >>A


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BALANCER SHAFT AND OIL PUMP MOD-

ULE REMOVAL

CAUTION


Never turn the crankshaft after the number 1 cylinder or

number 4 cylinder is set to the top dead center of com-

pression.

1. Turn the crankshaft clockwise to align the timing mark of thebalancer shaft sprocket with the timing mark of the balancershaft and oil pump module, and set the number 1 cylinder ornumber 4 cylinder to the top dead center of compression.

2. Put paint mark on the balancer shaft sprocket timing markand balancer timing chain.

CAUTION

Securely install the plunger of the timing chain tensioner.

Otherwise, it may pop out.

3. Press the balancer timing chain against the timing chaintensioner, compress the plunger of the timing chaintensioner and insert L-shaped hard wire (piano wire, etc.) orL-shaped hexagon wrench [1.5 mm (0.05 inch)] to theplunger fixing hole of the timing chain tensioner from underthe timing chain case, and fix the plunger of the timing chaintensioner.

AC509275AB

Balancer shaftsprockettiming mark

Paintmarkings

Balancershaft andoil pumpmoduletiming mark

AC509276AB

L-shaped hard wire orL-shaped hexagon wrench


AC509277AB

L-shaped hard wire orL-shaped hexagon wrench

Timing chaintensionerBalancer

timing chain


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4. Use a wrench to remove the mounting bolt at the lower sideof the balancer timing chain guide shown in the figure sothat the balancer timing chain guide is unrestricted.

5. Support the balancer shaft and oil pump module with ahand, and remove the balancer shaft and oil pump modulemounting bolts.

6. Remove the balancer shaft and oil pump module from therudder frame with the balancer timing chain attached, andmove it to the center of the engine.

7. Remove the balancer timing chain from the balancer shaftand oil pump module, and remove the balancer shaft and oilpump module.

CAUTION

When the tooth jump of the balancer timing chain from the

crankshaft sprocket occurs, the timing between the bal-

ancer shaft and the oil pump module becomes off, result-

ing in the abnormal engine vibration. Be sure that the tooth

jump will not occur.

8. After the balancer shaft and oil pump module is removed,using a cable band, tie the balancer timing chain at theprotrusion of the rudder frame to prevent the tooth jump ofbalancer timing chain from the crankshaft sprocket.

INSTALLATION SERVICE POINT.

>>A


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(1) Clean the inside of the removed engine oil pan, and putthe balancer shaft and oil pump module into the engineoil pan with its oil inlet port facing up.

(2) Pour new engine oil until two-thirds of the balancer shaftand oil pump module is soaked.

(3) Fill the new engine oil [approximately 50 cm3(3.05cu.in.)] into the balancer shaft and oil pump module from

the oil inlet port.

(4) Turn the balancer shaft sprocket of the balancer shaftand oil pump module clockwise four rotations or more toapply the engine oil to the entire area of the oil pump andthe balancer shaft bearing.

2. Remove the cable band installed to prevent the tooth jumpof the balancer timing chain from the crankshaft sprocketfrom the balancer timing chain.

3. Regarding the prevention of the tooth jump of the balancertiming chain, install the balancer shaft sprocket to thebalancer timing chain with aligning the paint mark of thebalancer shaft sprocket (the timing mark of the new balancershaft and oil pump module) with that of the balancer timingchain.

4. With the paint mark of the balancer timing chain aligned withthat of the balancer sprocket (the timing mark of the newbalancer shaft and oil pump module), install the balancer

shaft and oil pump module to the rudder frame. Securelybring the balancer shaft and oil pump module into contactwith the rudder frame mounting area.

5. Apply an adequate and minimum amount of engine oil to thethreads and bearing surfaces of the balancer shaft and oilpump module mounting bolts.

6. Tighten the balancer shaft and oil pump module mountingbolts to the specified torque in the order of number shown inthe figure.


7. Retighten the balancer shaft and oil pump module mounting

bolts to the specified torque in the order of number shown inthe figure.


8. Loosen each balancer shaft and oil pump module mountingbolts fully in the reverse sequence to that shown.

9. Tighten the balancer shaft and oil pump module mountingbolts again to the specified torque in the order of numbershown in the figure.


AC509272 AB

Oil inletport

Engineoil

Engineoil pan

Balancer shaft and oil pump module

AC509273 AB

Balancer

shaftsprocket

Balancer shaft and oil pump module

AC509279AC

Balancertimingchain

Paint markings

Balancer shaftsprocket

Paint markingor timing mark

AC506784 AB

1

2

3

4



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10.After tightening to the specified torque, tighten the balancershaft and oil pump module mounting bolts to 135 degreesangle, using special tool MB991614, in the order of numbershown in the figure.

11.Tighten the mounting bolt of the lower side of the balancertiming chain guide with the standard torque.

Tightening torque: 10 2 N m (89 17 in-lb)

12.Remove the plunger of the timing chain tensioner using theL-shaped hard wire (piano wire, etc.) or L-shaped hexagonwrench [1.5 mm (0.05 inch).]

AC506784 AB

1

2

3

4


AC506777AB

MB991614



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ENGINE ASSEMBLY

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ENGINE ASSEMBLYREMOVAL AND INSTALLATION

M1112001005695

CAUTION

When the engine assembly replacement is performed, use scan tool MB991958 to initialize the learn-

ing value (Refer to GROUP 00, Initialization Procedure for Learning Value in MFI Engine P.00-38.)

Pre-removal Operation Hood Removal (Refer to GROUP 42A, Hood P.42A-7.) Fuel Line Pressure Reduction (Refer to GROUP 13B,

On-vehicle Service How to Reduce Pressurized FuelLines P.13B-1000.)

Engine Room Under Cover Front A, B and Engine RoomSide Cover Removal (Refer to GROUP 51, Under CoverP.51-20.)

Engine Coolant Draining (Refer to GROUP 14, On-vehicleService Engine Coolant Replacement P.14-26.)


Transmission Oil Draining (Refer to GROUP 22A,On-vehicle Service Transmission Oil Replacement

P.22A-8) Transmission Fluid Draining (Refer to GROUP 23A,On-vehicle Service Transmission Fluid ReplacementP.23A-136)

Engine Upper Cover Removal (Refer to P.11C-24.) Exhaust Manifold Removal (Refer to GROUP 15, Exhaust

Manifold P.15-26.) Air Cleaner Assembly Removal (Refer to GROUP 15, Air

Cleaner P.15-10.) Battery and Battery Tray Removal (Refer to GROUP 54A,

Battery P.54A-10.) Engine control module Removal (Refer to GROUP 13B,

Engine Control Module P.13B-1022.) Radiator Removal (Refer to GROUP 14, Radiator

P.14-53.)

Drive Belt Removal (Refer to P.11C-19.)

Post-installation Operation Drive Belt Installation (Refer to P.11C-19.) Radiator Installation (Refer to GROUP 14, Radiator

P.14-53.) Engine control module Installation (Refer to GROUP 13B,

Engine Control Module P.13B-1022.) Battery and Battery Tray Installation (Refer to GROUP

54A, Battery P.54A-10.) Air Cleaner Assembly Installation (Refer to GROUP 15,

Air Cleaner P.15-10.) Exhaust Manifold Installation (Refer to GROUP 15,

Exhaust Manifold P.15-26.) Transmission Oil Draining (Refer to GROUP 22A,

On-vehicle Service Transmission Oil Replacement

P.22A-8) Transmission Fluid Draining (Refer to GROUP 23A,On-vehicle Service Transmission Fluid ReplacementP.23A-136)

Engine Oil Refilling (Refer to GROUP 12, On-vehicle Ser-vice Engine Oil Replacement P.12-5.)

Engine Coolant Refilling (Refer to GROUP 14, On-vehicleService Engine Coolant Replacement P.14-26.)

Drive Belt Tension Check (Refer to P.11C-8.) Fuel Leak Check. Engine Room Under Cover Front and Engine Room Side

Cover Installation (Refer to GROUP 51, Under CoverP.51-20.)

Engine Upper Cover Installation (Refer to P.11C-24.) Hood Installation (Refer to GROUP 42A, Hood P.42A-7.)
http://gr00002700-00.pdf/http://gr00002400-42a.pdf/http://gr00001300d-13b.pdf/http://gr00003700-51.pdf/http://gr00001500-14.pdf/http://gr00001000-12.pdf/http://gr00004300-22a.pdf/http://gr00004800-23a.pdf/http://gr00001600-15.pdf/http://gr00001600-15.pdf/http://gr00002900a-54a.pdf/http://gr00001300d-13b.pdf/http://gr00001500-14.pdf/http://gr00001500-14.pdf/http://gr00001300d-13b.pdf/http://gr00002900a-54a.pdf/http://gr00001600-15.pdf/http://gr00001600-15.pdf/http://gr00004300-22a.pdf/http://gr00004800-23a.pdf/http://gr00001000-12.pdf/http://gr00001500-14.pdf/http://gr00003700-51.pdf/http://gr00002400-42a.pdf/http://gr00002400-42a.pdf/http://gr00003700-51.pdf/http://gr00001500-14.pdf/http://gr00001000-12.pdf/http://gr00004800-23a.pdf/http://gr00004300-22a.pdf/http://gr00001600-15.pdf/http://gr00001600-15.pdf/http://gr00002900a-54a.pdf/http://gr00001300d-13b.pdf/http://gr00001500-14.pdf/http://gr00001500-14.pdf/http://gr00001300d-13b.pdf/http://gr00002900a-54a.pdf/http://gr00001600-15.pdf/http://gr00001600-15.pdf/http://gr00004800-23a.pdf/http://gr00004300-22a.pdf/http://gr00001000-12.pdf/http://gr00001500-14.pdf/http://gr00003700-51.pdf/http://gr00001300d-13b.pdf/http://gr00002400-42a.pdf/http://gr00002700-00.pdf/


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ENGINE ASSEMBLY

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AC506785AC

1

7

4

3

6

5

12 2 Nm102 22 in-lb

8

9

2

8.5 1.5 Nm76 13 in-lb

Removal steps

1. Control wiring harness connection2. Battery cable connection

>>E>E>D


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ENGINE ASSEMBLY

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MB991454: Engine Hanger Balancer MB991895: Engine Hanger

MB991928: Engine Hanger MB992201: Engine Hanger Plate

AC609240AC

10

11

14

13

25 4 Nm18 3 ft-lb

23 6 Nm17 4 ft-lb

9.0 2.0 Nm80 17 in-lb

50 5 Nm37 3 ft-lb

66 7 Nm49 5 ft-lb

12

13 2 Nm111 22 in-lb

Removal steps

10. Power steering oil pump assembly >>C>B>A


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ENGINE ASSEMBLY

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RADIATOR UPPER HOSE/RADIATOR

LOWER HOSE DISCONNECTIONMake mating marks on the radiator hose and the hose clampas shown to install them in the original position. Then, removethem.

.

FUEL HIGH-PRESSURE HOSE

DISCONNECTION1. Remove the stopper of the fuel high-pressure hose.

2. Raise the retainer of the fuel high-pressure hose and pull outthe fuel high-pressure hose in the direction shown in thefigure.

NOTE: If the retainer is released, install it securely after

removing the fuel high-pressure hose.

.


REMOVAL1. Remove the power steering oil pump assembly together with

the hose from the bracket.

2. Tie the removed power steering oil pump assembly with astring at a position where it will not interfere with the removaland installation of engine assembly.

.

AC606081

Mating marks

AH

AC301860AC

Stopper

AC301861AC

Retainer


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ENGINE ASSEMBLY

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A/C COMPRESSOR AND CLUTCH

ASSEMBLY REMOVAL

1. Remove the A/C compressor and clutch assembly togetherwith the hose from the bracket.

2. Tie the removed A/C compressor and clutch assembly witha string at a position where it will not interfere with the

removal and installation of engine assembly..

MANUAL TRANSAXLE ASSEMBLY

/CVT ASSEMBLY REMOVAL1. Install the front end upper bar bolts to the position as shown

in the figure.

2. Remove the transaxle assembly (Refer to GROUP 22A,Transaxle Assembly P.22A-12) or (Refer to GROUP23A, Transaxle Assembly P.23A-152)

.

ENGINE MOUNTING INSULATOR

REMOVAL

CAUTION

When supporting the engine assembly with a garage jack,

be careful not to deform the engine oil pan.

1. Place a garage jack against the engine oil pan with a pieceof wood in between to support the engine assembly.

AC609445AB
http://gr00004300-22a.pdf/http://gr00004800-23a.pdf/http://gr00004800-23a.pdf/http://gr00004300-22a.pdf/


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ENGINE ASSEMBLY

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2. Remove special tool MB991928 or MB991895 andMB992201 which was installed for supporting the engineassembly when the transaxle assembly was removed (Referto GROUP 22A, Transaxle Assembly P.22A-12) or(Refer to GROUP 23A, Transaxle Assembly P.23A-152)

3. Operate a garage jack so that the engine weight is not

applied to the engine mounting insulator, and remove theengine mounting insulator.

.

ENGINE ASSEMBLY REMOVAL1. Mount the special tool MB991454 to the power steering oil

pump bracket and the engine hanger, and set the chainblock.

2. After checking that all cables, hoses and wiring harnessconnectors and so on are disconnected from the engine, liftthe engine assembly slowly with the chain block to removethe engine assembly upward from the engine compartment.

AC611566AB

MB991928

AC611563AE

MB991895

AC611567AB

MB992201

AC609297

AC611556AB

MB991454
http://gr00004300-22a.pdf/http://gr00004800-23a.pdf/http://gr00004800-23a.pdf/http://gr00004300-22a.pdf/


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ENGINE ASSEMBLY

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>>A>B


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ENGINE ASSEMBLY

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3. Install special tool MB992201 and MB991928 or MB991895which is used during installation of transaxle assembly tohold the engine assembly (Refer to GROUP 22A, Transaxle

Assembly P.22A-12) or (Refer to GROUP 23A,Transaxle Assembly P.23A-152)

.

>>C


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ENGINE ASSEMBLY

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>>D>E


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NOTES

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